Apparatus for assembling refastenable absorbent garments

ABSTRACT

An apparatus for fabricating the refastenable absorbent garment includes a web perforator adapted to perforate a base web in a cross direction and a construction drum positioned downstream of the web perforator and adapted to receive the perforated base web. A landing material cutter is adapted to cut a landing material and fastener material in the cross direction. A landing member rotator is positioned adjacent the construction drum and downstream of the landing material cutter. The landing member rotator is adapted to separate successive pieces of the landing material with the fastener material attached thereto at the cross direction landing material cut, rotate the pieces of landing material with the fastener member attached thereto and apply the piece of landing material and fastener material to the base web on the construction drum.

This application is a division of U.S. application Ser. No. 09/954,480,filed Sep. 14, 2001, now issued as U.S. Pat. No. 6,682,626, the entiredisclosure of which is hereby incorporated herein by reference.

BACKGROUND

The present invention relates generally to a refastenable absorbentgarment, and in particular, to a method and apparatus for assembling arefastenable absorbent garment having a fastener that refastenablyengages a landing member.

Absorbent garments can be configured in many different forms. Forexample, absorbent garments can be configured as a pant-type, pull-ongarment, or as a diaper-type product that is drawn up between the legsand fastened about the waist with various fastening systems. Pant-type,pull-on garments are often provided with various elastic elements thatcan conform to the body of the user and provide a comfortable, snug fit.Such garments, however, often do not have a refastenable mechanism thatallows the garment to be easily removed after use or to be adjustedduring use.

On the other hand, diaper-type products, which can be configured withfastening systems that allow the user to detach and reattach variousfasteners so as to provide a refastenable absorbent garment, often arenot configured with various elastic elements, for example around thewaist, and may not conform well to the body of the user and/or mayprovide a bulky appearance beneath the user's garments. Moreover, suchgarments are typically produced as an “open” product, which is open atthe sides and which cannot be pulled on like a pant-type garment. Someusers prefer a pull-on type garment, since the garment is applied to theuser like conventional underwear. Therefore, there remains a need for animproved absorbent garment, and in particular a pant-type garment, thatis refastenable and provides a snug fit with a non-bulky appearance.

In addition, manufacturing facilities are often configured to fabricateone particular type of product. As such, these facilities may notprovide the flexibility to transition between fabricating a pull-on typegarment and fabricating a refastenable, pull-on type garment using asingle manufacturing line or asset. Therefore the need also remains forimproved methods and assemblies for manufacturing refastenable absorbentgarments.

SUMMARY

Briefly stated, in one aspect, the invention is directed to a method forassembling a refastenable absorbent garment. The method comprises movinga landing material in a machine direction, wherein the landing materialhas opposite lateral side edges, moving a fastener material in a machinedirection, wherein the fastener material comprises a refastenableportion and a base portion, and removeably attaching the refastenableportion of the fastener material to at least one of the side edges ofthe landing material. The method preferably further includessuccessively cutting the landing material with the fastener materialremoveably attached thereto along a cross direction and thereby forminga plurality of landing members with a fastener member removeablyattached thereto and successively rotating each of the plurality oflanding members with the fastener member removeably attached thereto. Inone preferred embodiment, the landing member with the fastener memberremoveably attached thereto is rotated approximately 90 degrees. Themethod preferably further includes moving a base web in a machinedirection, successively attaching each of the landing members to thebase web and attaching the base portion of the fastener member to thebase web.

In one preferred embodiment of the invention, the method furthercomprises moving a pair of strips of fastener material in a machinedirection and attaching the strips to the opposite lateral side edges ofthe landing material. In another preferred embodiment, the methodfurther comprises applying an adhesive to the base web, and placingelastic strands on the base web along the machine direction.

In yet another preferred embodiment, the method further comprisescutting the base web along a cross direction and attaching the landingmember and fastener member to the base web on opposite sides of thecross direction cut. In one preferred embodiment, the cross directioncut is formed as a perforation.

In another aspect of the invention, an apparatus for fabricating arefastenable absorbent garment includes a web perforator adapted toperforate the base web in a cross direction and a construction drumpositioned downstream of the web perforator and adapted to receive thebase web. The apparatus also preferably includes a landing materialcutter adapted to cut the landing material and fastener material in thecross direction, and a landing member rotator positioned adjacent theconstruction drum. The landing member rotator is adapted to separatesuccessive pieces of the landing material with the fastener materialattached thereto at the cross direction landing material perforation,rotate the pieces of landing material with the fastener member attachedthereto and apply the landing member and fastener member to the base webon the construction drum.

The present invention provides significant advantages over otherabsorbent garments and methods and apparatus for the manufacturethereof. For example, in one embodiment of a pant-type garment, the usercan pull the garment on or off like underwear. However, by making theabsorbent garment refastenable, it can be applied without needing topull the garment on or off like a pant-like garment, if desired. Forexample, the garment can be pulled on like a pant-type garment, andremoved like a diaper-type product by disengaging the fastener membersand breaking the lines of weakness. Alternatively, the garment can bepulled on and off like a pant-like garment, and can thereafter beconverted to a refastenable garment, if desired. For example, thegarment can be made bigger or smaller simply by adjusting thepositioning of the fasteners. Moreover, in one particular application,wherein the garment is used by adults, for example with occasionalincontinence problems, the garment can be pulled up or down by the user,or the fastening system may be disengaged and engaged repeatedly by theuser while the garment remains unsoiled over an extended period of time.

In one preferred embodiment, the absorbent garment includes elasticelements extending along the waist region. The elastic elements providea snug, comfortable fit that does not create a bulky appearance beneaththe user's outer garments. The combination of the refastenable fastenerswith the elastic elements further enhances the fit and appearance of thegarment.

At the same time, the separate assembly of a refastenable subassembly,comprising a landing member and at least one fastener removeably securedthereto, allows the manufacturer to switch easily between making anon-refastenable, pant-type product and a refastenable, pant-typeproduct. In particular, the process of rotating the refastenablesubassembly and attaching it to the base web can be omitted if desired.

In addition, the fabrication of the refastenable subassembly is greatlysimplified by removeably attaching the refastenable portion of thefastener material to the landing material, preferably without any otherbonds or fasteners disposed therebetween. In this way, the refasteningmechanism, and in particular the interface between the refastenableportion and the landing material, which provides flexibility to the userwhen wearing the absorbent garment, also provides a simple and efficientway to maintain the position and relationship between the fastenermember and the landing member during the manufacturing process. As such,the cost of the system and its operation can be minimized.

The present invention, together with further objects and advantages,will be best understood by reference to the following detaileddescription taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of one embodiment of a refastenableabsorbent garment in a fastened configuration.

FIG. 2 is a schematic top view representation of a method of fabricatinga front body panel of the refastenable absorbent garment.

FIG. 3 is a schematic side view representation of an apparatus for andmethod of fabricating the front body panel.

FIG. 4 is a schematic top view representation of a method of fabricatinga refastenable absorbent garment.

DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS

It should be understood that the term “longitudinal,” as used herein,means of or relating to length or the lengthwise direction, and inparticular, the direction running between the front and back of theuser. The term “laterally,” as used herein means situated on, directedtoward or running from side to side, and in particular, a directionrunning from the left to the right of a user, and vice versa. The terms“upper,” “lower,” “inner,” and “outer” as used herein are intended toindicate the direction relative to the user wearing an absorbent garmentover the crotch region, while the terms “inboard” and “outboard” referto the directions relative to a centerline 8 of the garment. Forexample, the terms “inner” and “upper” refer to a “bodyside,” whichmeans the side closest to the body of the user, while the terms “outer”and “lower” refer to a “garment side.”

The term “bodyside” should not be interpreted to mean in contact withthe body of the user, but rather simply means the side that would facetoward the body of the user, regardless of whether the absorbent garmentis actually being worn by the user and regardless of whether there areor may be intervening layers between the component and the body of theuser. Likewise, the term “garment side” should not be interpreted tomean in contact with the garments of the user, but rather simply meansthe side that faces away from the body of the user, and therefore towardany outer garments that may be worn by the user, regardless of whetherthe absorbent garment is actually being worn by a user, regardless ofwhether any such outer garments are actually worn and regardless ofwhether there may be intervening layers between the component and anyouter garment.

The term “machine direction” means the direction of flow as the variousmembers and webs progress along the fabrication line and process. Itshould be understood that various separate members or webs can each betraveling in a machine direction, but with the various machinedirections not necessarily being parallel or oriented in the samedirection. For example, one web may be traveling a first machinedirection, which is substantially perpendicular to the travel of anotherweb in a second machine direction.

The term “cross direction” means the direction substantiallyperpendicular to the machine direction.

The term “downstream” means that one item is positioned more closely tothe output or finished product end of the machine and/or processrelative to another item. Conversely, the term “upstream” means that anitem is positioned more closely to the input end of the machine orprocess relative to another item. For example, the output end isdownstream of the input end, and vice versa, the input end is upstreamof the output end.

The phrases “removeably attached,” “removeably attaching,” “removeablyconnected,” “removeably engaged,” “releasably attached,” “releasablyconnected,” or “releasably engaged,” and variations thereof, refers totwo or more elements being connected or connectable such that theelements tend to remain connected absent a separation force applied toone, both or all of the elements, and where the elements are capable ofbeing separated upon the application of a separation force. The requiredseparation force is typically beyond that encountered while wearing theabsorbent garment.

The phrases “fixedly secured,” “fixedly engaged,” “fixedly attached,”“fixedly connected,” and variations thereof, refers to two or moreelements being connected or connectable such that they are notdisconnected or otherwise separated, and are not intended to beseparated or disconnected, during the normal operation and use of theabsorbent garment.

The term “web” refers to a continuous stream of material, whether madefrom one or more layers or substrates, and regardless of whether it mayhave non-continuous, discrete items disposed thereon.

Referring to FIG. 1, an absorbent garment 2 includes a first, front bodypanel 4 and a second, rear body panel 6. The term “body panel” refers tothe portion(s) of the absorbent garment, whether made of one or morelayers or substrates or of one or more pieces or components, that is/arefitted circumferentially around at least the waist region of the user,including for example the user's lower back, buttock, hips and abdomen.The first and second body panels each have an inner, bodyside surface 10and an outer, garment side surface 12. The first, front body panel 4 hasa length, which is measured between opposed first and second terminaledges 16 and 20, and which is less than the overall length of theabsorbent garment. Likewise, the second, rear body panel 6 has anoverall length, which is measured between opposed first and secondterminal edges 14 and 18, and which is also less than the overall lengthof the absorbent garment. Each of the first and second body panels hasan outboard edge 24, 28 formed along the outer periphery of laterallyopposed side portions of the first and second body panel. It should beunderstood that the outboard edges of the front and rear body panels canbe different lengths.

Referring to FIG. 1, one or more, and preferably a plurality, meaningtwo or more, laterally extending elastic elements 36 are secured to eachof the first and second body panels. In one preferred embodiment, aplurality of laterally extending elastic elements are longitudinallyspaced across substantially the entire length of the waist portion ofthe front and rear body panel 4,6, although they may be spaced across alesser length. For example, elastic elements can extend along the upperwaist portion and along the lower terminal edge defining in part a legopening 120. In one embodiment, the front body panel has a“non-elasticized” area wherein there are no laterally extending elasticelements, or other elastic or elastomeric backing members, incorporatedtherein or making up any portion of the thickness or cross-section ofthe body panel at that area, such that the material can be gathered. Itshould be understood, that in an alternative embodiment, one or moreseparate waist bands, with or without elastic elements, can be securedto one or both of the rear and front body panels, preferably along theupper terminal edges thereof. In addition, one or both of the bodypanels can be formed without any elastic elements.

The front body panel preferably has a “deactivated” area 17 wherein theelastic elements are severed, chopped or otherwise deactivated, forexample by using a rotary die cutter, by melt-breaking (e.g. with aheated or ultrasonic function roll) or by any other means know to thoseskilled in the art. In one preferred embodiment, the deactivated area 17or landing zone is formed along a center portion of the front body paneland underlies a landing member 100 and a pair of fastener members. Oneor more leg elastic elements 38 can be secured along the inner terminaledges of the body panels 4, 6 and an absorbent composite 50 to form agasket with the leg of the user.

The various waist and leg elastic elements can be formed from rubber orother elastomeric materials. One suitable material is a LYCRA® elasticmaterial. For example, the various elastic elements can be formed ofLYCRA® XA Spandex 540, 740 or 940 detex T-127 or T-128 elasticsavailable from E.I. duPont De Nemours and Company, having an office inWilmington, Del.

Each body panel is preferably formed as a composite, or laminatematerial, otherwise referred to as substrates or laminates, with theplurality of elastic strands sandwiched therebetween. Preferably two ormore layers are bonded with various adhesives, such as hot melt, or byother techniques, including for example and without limitationultrasonic bonding and heat pressure sealing. In one embodiment, the twolayers are made of a non-woven material. It should be understood thatthe body panels can be made of a single layer or substrate of non-wovenmaterial, or can be comprised of more than two layers or substrates. Ofcourse, it should be understood that other knitted or woven fabrics,non-woven fabrics, elastomeric materials, polymer films, laminates andthe like can be used to form one or more of the body panel layers. Theterm “non-woven” web or material, as used herein, means a web having astructure of individual fibers or filaments that are interlaid, but notin an identifiable manner and without the aid of textile weaving orknitting, as in a knitted or woven fabric.

In one embodiment, the non-woven layers or substrates, and also alanding material 102, can be made by spunbonding. Spunbond nonwoven websor materials are made from melt-spun filaments or spunbonded fiberswhich refers to small diameter fibers that are formed by extrudingmolten thermoplastic material as filaments from a plurality of fine,usually circular capillaries of a spinneret with the diameter of theextruded filaments then being rapidly reduced, for example, bynon-eductive or eductive fluid-drawing or other well known spunbondingmechanisms. The production of spunbound nonwoven webs is described inU.S. Pat. No. 4,340,563 to Appel et al., U.S. Pat. No. 3,692,618 toDorschner et al., U.S. Pat. No. 3,802,817 to Matsuki et al, U.S. Pat.No. 3,502,763 to Hartmann, U.S. Pat. No. 3,276,944 to Levy, U.S. Pat.No. 3,502,538 to Peterson, and U.S. Pat. No. 3,542,615 to Dodo et al,all of which are incorporated herein by reference. The melt-spunfilaments formed by the spunbond process are generally continuous andhave diameters larger than 7 microns, more particularly, between about10 and 30 microns. Another frequently used expression of fiber orfilament diameter is denier, which is defined as grams per 9000 metersof a fiber or filament. The fibers may also have shapes such as thosedescribed in U.S. Pat. No. 5,277,976 to Hogle, et al, U.S. Pat. No.5,466,410 to Hills and U.S. Pat. Nos. 5,069,970 and 5,057,368 to Largmanet al., all of which are incorporated herein by reference. The spunbondfilaments usually are deposited, by one or more banks, onto a movingforaminous belt or forming wire where they form a web. Spunbondedfilaments generally are not tacky when they are deposited onto thecollecting surface.

Spunbond fabrics typically are stabilized or consolidated (pre-bonded)in some manner immediately as they are produced in order to give the websufficient integrity to withstand the rigors of further processing intoa finished product. This stabilization (prebonding) step may beaccomplished through the use of an adhesive applied to the filaments asa liquid or powder which may be heat activated, or more commonly, bycompaction rolls. As used herein, the term “compaction rolls” means aset of rollers above and below the web used to compact the web as a wayof treating a just produced, melt-spun filament, particularly spunbond,web, in order to give the web sufficient integrity for furtherprocessing, but not the relatively strong bonding of secondary bondingprocesses, such as through-air bonding, thermal bonding, ultrasonicbonding and the like. Compaction rolls slightly squeeze the web in orderto increase its self-adherence and thereby its integrity.

An alternative means for performing the pre-bonding step employs a hotair knife, as described in U.S. Pat. No. 5,707,468, the entirety ofwhich is hereby incorporated herein by reference. Briefly, the term “hotair knife” means a process of pre-bonding a just produced melt-spunfilament, particularly spunbond, web, in order to impart the web withsufficient integrity, i.e., increase the stiffness of the web, forfurther processing. A hot air knife is a device that focuses a stream ofheated air at a very high flow rate, generally from about 300 to about3000 meters per minute (m/min.), or more particularly from about 900 toabout 1500 m/min., directed at the nonwoven web immediately after itsformation. The air temperature usually is in the range of the meltingpoint of at least one of the polymers used in the web, generally betweenabout 90° C. and about 290° C. for the thermoplastic polymers commonlyused in spunbonding. The control of air temperature, velocity, pressure,volume and other factors helps avoid damage to the web while increasingits integrity.

The hot air knife's focused stream of air is arranged and directed by atleast one slot of about 3 to about 25 millimeters (mm) in width,particularly about 9.4 mm, serving as the exit for the heated airtowards the web, with the slot running in a substantially cross-machinedirection over substantially the entire width of the web. In otherembodiments, there may be a plurality of slots arranged next to eachother or separated by a slight gap. The at least one slot usually, butnot necessarily, is continuous, and may be comprised of, for example,closely spaced holes. The hot air knife has a plenum to distribute andcontain the heated air prior to its exiting the slot. The plenumpressure of the hot air knife usually is between about 2 to about 22mmHg, and the hot air knife is positioned between about 6.35 mm andabout 254 mm, and more particularly from about 19.05 to about 76.20 mmabove the forming surface. In a particular embodiment, the hot air knifeplenum's cross-sectional area for cross-directional flow (i.e., theplenum cross-sectional area in the machine direction) is at least twicethe total slot exit area. Since the foraminous wire onto which spunbondpolymer is formed generally moves at a high rate of speed, the time ofexposure of any particular part of the web to the air discharge from thehot air knife typically is less than a tenth of a second and generallyabout one hundredth of a second, in contrast with the through-airbonding process, which has a much longer dwell time. The hot air knifeprocess has a great range of variability and control over many factors,including air temperature, velocity, pressure, and volume, slot or holearrangement, density and size, and the distance separating the hot airknife plenum and the web.

The spunbond process also can be used to form bicomponent spunbondnonwoven webs as, for example, from side-by-side (or sheath/core) linearlow density polyethylene/polypropylene spunbond bicomponent filaments. Asuitable process for forming such bicomponent spunbond nonwoven webs isdescribed in U.S. Pat. No. 5,418,045 to Pike et al., which isincorporated herein by reference in its entirety.

Commercially available thermoplastic polymeric materials can beadvantageously employed in making the fibers or filaments from whichpattern-unbonded nonwoven material is formed. As used herein, the term“polymer” shall include, but is not limited to, homopolymers,copolymers, such as, for example, block, graft, random and alternatingcopolymers, terpolymers, etc., and blends and modifications thereof.Moreover, unless otherwise specially limited, the term “polymer” shallinclude all possible geometrical configurations of the material,including, without limitation, isotactic, syndiotactic and randomsymmetries. As used herein, the terms “thermoplastic polymer” or“thermoplastic polymeric material” refer to a long-chain polymer thatsoftens when exposed to heat and returns to its original state whencooled to ambient temperature. Preferably, the spunbond fibers are madeof a polypropylene. Other alternative thermoplastic materials include,without limitation, poly(vinyl chloride)s, polyesters, polyamides,polyfluorocarbons, polyolefins, polyurethanes, polystyrenes,polyethylenes, poly(vinyl alcohol)s, caprolactams, and copolymers of theforegoing. The fibers or filaments used in making the nonwoven materialmay have any suitable morphology and may include hollow or solid,straight or crimped, single component, bicomponent or multicomponent,biconstituent or multiconstituent fibers or filaments, and blends ormixes of such fibers and/or filaments, as are well known in the art.

After the nonwoven web is formed, the pre-bonded or unbonded web ispassed through a suitable process or apparatus, including for example acalendar roll, to form a pattern of discrete bonded areas. The term“discrete” as used herein means individual or disconnected, and iscontrasted with the term “continuous” as used in U.S. Pat. No. 5,858,515to Stokes et al, the entirety of which is hereby incorporated herein byreference, and which describes pattern-unbonded, or point un-bonded,nonwoven fabrics having continuous bonded areas defining a plurality ofdiscrete unbonded areas. In one embodiment, the calendar stack (notshown) includes an anvil roll and a pattern roll, which is heated andincludes various raised landing portions. The raised portions of thepattern roll thermally bond the fibers to form the bonded areas. Thebonds can made of any shape and size. Preferably, the percent bondedarea of the web is between about 5% and 25% of the area of the web, andis more preferably between about 10% and 15%. Thereafter, the bondedsubstrate can be bonded to another substrate with the elastic membersdisposed therebetween.

In one alternative preferred embodiment, the landing material 102 ismade of a point-unbonded nonwoven material, for example, a 2.0 osypoint-unbonded material. One exemplary material of this type has beenused in a HUGGIES® Ultratrim Disposable Diaper, which is commerciallyavailable from Kimberly-Clark Corporation. In another preferredembodiment, the landing material is made of a non-woven material, forexample, a spunbond material having a basis weight of preferably about0.6 osy. In other preferred embodiments, the basis weight of eachsubstrate can be between at least about 0.3 and about 2.0 osy, andpreferably between about 0.5 osy and about 1.5 osy, and more preferablybetween about 0.5 osy and about 1.0 osy. Even with a relatively lowpercent area bonding, the relatively low basis weight non-woven materialexhibits strength and tear characteristics allowing it to be used as abody panel. Other materials that may be used as the non-woven materialinclude various meltblown materials, and also bonded-carded materials.

In other alternative embodiments, the landing material can be made of aloop material, which typically includes a backing structure and aplurality of loop members extending upwardly therefrom. The loopmaterial can be formed from any suitable material, such as acrylic,nylon or polyester, and can be formed by such methods as warp knitting,stitch bonding or needle punching. Suitable loop materials are availablefrom Guilford Mills, Inc., Greensboro, N.C., U.S.A. under the tradedesignation No. 36549.

The body panel 4, 6 non-woven material is preferably substantiallyhydrophobic, which may optionally be treated with a surfactant orotherwise process to impart a desired level of wettability andhydrophilicity. In one particular embodiment of the invention, the bodypanel is a nonwoven, wire-weave spunbond polypropylene fabric composedof about 1.6 denier fibers formed into a web having a basis weight ofabout 0.6 osy. One suitable non-woven material is the Corinth 0.60 osy,1.6 dpf wireweave, nonwettable Metallocene (EXXON ACHIEVE 2854 PP)spunbond material manufactured by Kimberly-Clark Corporation, theassignee of the present application.

Referring to FIG. 1, fastening members or tabs 42 are preferablyattached to the front body panel and extend laterally inboard relativeto the outboard side edge 24 of the front body panel 4 from anattachment location 45, which is preferably spaced inboard from the sideedge. The front body panel 4 includes a middle portion 33, having alanding member 100 secured thereto, and opposite side portions 35.Opposite longitudinally extending lines of weakness 37 separate themiddle portion 33 with the landing member 100 attached thereto, from theopposite side portions 35, such that the side portions 35 are initiallybreakably attached to opposite sides of the middle portion 33. The linesof weakness 37 can comprise a perforation or other series of cuts, athinning, breakage or separation of material, or a strip of a differentkind of material bridging between the middle portion and the sideportions that is more easily torn or broken than the material of themiddle portion and side portions, which allow a user or the manufacturerto separate the side portions from the middle portion. For example, theabsorbent garment can be broken after the garment is applied to a user,or beforehand. Preferably, the fastening members 42 are secured to thegarment-side surface of the side portions 35, preferably in a portion ofthe deactivacted zone 17, between the side edge 24 of the front bodypanel and the line of weakness 37.

It should be understood that, in other embodiments, the fasteningmembers can be secured to the rear body panel and engage the front bodypanel or, conversely, can be secured to the front body panel and engagethe rear body panel, preferably along at least a portion that is notelasticized. Preferably, the fastening members are fixedly secured tothe outer, garment-side surface of the front and/or rear body panels,and releasably engage the outer, garment-side surface of the frontand/or rear body panels, although it should be understood that thefastening members could be fixedly secured to an inner body-side surfaceof front and/or rear body panels and releasably engage an inner,body-side surface of the front and/or rear body panels.

The opposite side edges 24 of the front body panel 4 are joined to theopposite side edges 28 of the rear body panel 6 to form a seam 39. Theseam 39 is formed by bonding, sewing or otherwise attaching the sideedges. In this way, prior to the breaking of the line of weakness 37,the absorbent garment can be configured as a pant-like garment, whichcan be pulled over the legs of the user. After the garment is applied tothe user, the lines of weakness can be broken, if desired, or leftintact, as the fasteners are adjusted to fit the garment to the user. Ifdesired, the lines of weakness can be broken prior to securing thegarment to the user, for example when the user is bed-ridden. In thisconfiguration, the garment is laid beneath the user and is secured tothe user with the fastening tabs. By providing the side portions, and byconnecting the fastening tabs to the front panel, instead of the rearbody panel, the tabs are located at the front of the user so as to notprovide discomfort to the user when lying on their backs and to allowthe fasteners to be more easily seen and adjusted by the user.

It should be understood that the lines of weaknesses and the fastenerscan be moved laterally inboard and outboard to provide more or lessadjustment capability. In addition, the elasticized side portionsprovide further adjustment capability.

It should be understood that the front and rear body panels can be madeas a unitary member that extends along the crotch from the front to backand with the sides thereof connected to form side seams. Alternatively,the front and rear body panels can be formed integrally, for example asone panel extending around the waist and hips of the user.

In one alternative embodiment, an outer cover is disposed over theentire garment and forms the outer garment-side layer or substrate ofthe front and rear body panels, with the various elastic elements 36, 38disposed between a bodyside liner on each of the front and rear bodypanels, which liner preferably is configured as a single substrate, andthe outer cover, which is also preferably configured as singlesubstrate. In this way, the portion of the outer cover that overlies thefront body panel liner and is fitted around the front of the user formspart of the front body panel, while the portion of the outer cover thatoverlies the rear body panel liner and is fitted around the rear of theuser forms part of the rear body panel. The front and rear body panels,with the liners and with the outer cover forming portions thereof andpreferably extending therebetween, forms a chassis. The outer cover ispreferably made of a non-woven material, similar to that of the otherbody panel materials described herein. It should be understood that thebody panels, including the outer cover, can be configured with anynumber of a plurality of substrates, and that the body panels caninclude other layers and substrates.

Preferably, as shown in FIG. 1, the fastening members 42 comprise acarrier member 43 that is formed in a generally side-ways, “U” shape,with a vertical extending base member 55 and a pair of laterallyextending and longitudinally spaced tab members 47. The carrier membercould also comprise one or more than two tab members. The carriermembers are preferably fixedly secured to the side portions of the frontbody panel 4 with adhesive bonds 49, sonic bonds, thermal bonds,pinning, stitching or other known types of attachment, as shown forexample in FIG. 1. In alternative embodiments, the fastening members canbe fixedly secured to the rear body panel or to one or both of the frontand rear body panels, e.g., at the seam.

Each carrier member 43 has a longitudinal length and each of the tabmembers 47 comprises a refastenable portion or an engagement portionhaving a longitudinal length. The refastenable portion 51 preferablycomprises an array of hooks, as explained below, but alternatively cancomprise various adhesives, such as pressure sensitive adhesives,buttons, zippers, snaps and other releasable and reattachable fasteningdevices know to those skilled in the art.

In one embodiment, shown in FIGS. 1 and 2, each fastening member 42 iscomprised of two separate, longitudinally spaced tab members 47. In anyof the embodiments, the two or more tab members provides a pant-like fitthat controls the waist and leg openings in the front and back of thegarment, and also allows the user to adjust the fit of the garmentwithout totally undoing the garment. For example, the user can releaseone of the tab members and refasten it without undoing the other tabmember.

In one preferred embodiment, the refastenable portion 51 comprises ahook-type fastener member, or hook strip, which is secured to thecarrier member 43 with adhesive, ultrasonic bonding, stitching or otherknown attachment devices. The end portion 53 or tip of the carriermember can be left uncovered by the refastenable portion 51, such thatit can be lifted or flexed and grasped by a user as they disengage orpeel back the fastener member. Alternatively, a portion of the array ofhook members can be deadened, so as to provide an area that will notengage with the landing material and can thereby be grasped by the user.It should be understood that the term “hook” as used herein means anyelement capable of engaging another element, and is not intended tolimit the form of the engaging elements, for example to include only“hooks,” but rather encompasses any form or shape of engaging element,whether unidirectional or bi-directional. Various hook configurationsare described in U.S. Pat. No. 5,845,375 to Miller et al., U.S. Pat. No.6,132,660 to Kampfer, U.S. Pat. No. 6,000,106 to Kampfer, U.S. Pat. No.5,868,987 to Kampfer, U.S. Pat. No. 4,894,060 to Nestegard, and U.S.Pat. No. 6,190,594 B1 to Gorman, the entire disclosures of which areincorporated by reference herein. Some examples of hook fasteners arethe various CS600 hook fasteners, including the XKH-01-002 CS600, 2300Pin Density hook fastener (Part No. XKH-01-002/60MM/SP#2628),manufactured by Minnesota Mining and Manufacturing Co., St. Paul Minn.Another example of a hook fastener is the Velcro® HTH-851 and HTH-829hook fasteners available from Velcro USA, Inc.

In one preferred embodiment, a mushroom-type hook strip comprises ahomogeneous backing of thermoplastic resin and, integral with backing,an array of upstanding stems distributed across at least one face of thebacking, each having a mushroom head. The array of hooks on each stripcomprise an engagement portion having a longitudinal length. The stemscan have a molecular orientation as evidenced by a birefringence valueof at least 0.001, and the mushroom heads having circular disc shapeswith generally planar end surfaces opposite the backing, which discshaped heads preferably have diameter to thickness ratios of greaterthan about 1.5 to 1.

The stems of the hook strip can be molecularly orientated as evidencedby a birefringence value of at least 0.001. As such, they havesignificantly greater stiffness and durability, as well as greatertensile and flexural strength, than would be achievable without suchorientation. Because of these qualities, the portions of the stems notheated by a heating surface during the forming process remainresiliently flexible during a deforming step, which preferably involvesthe application of heat to the stem tips by contact with the heatedsurface of a metal roller. Such contact forms the tip of each stem intoa circular disc shaped mushroom head at the tip of each stem, which headhas a substantially flat inner surface that enhances its holding powerwhen engaged with a loop.

As compared to hook strips that have unoriented stems, the enhancedstrength of the hooks of the hook strip makes them less likely to breakduring disengagement. When the hook strip is used with the non-wovenmaterial herein described, the enhanced strength of the hooks makes themless likely to break under disengagement forces than the fibers of thematerial, a beneficial attribute for at least two reasons. First, brokenhooks can create debris whereas a broken fiber typically does not.Furthermore, the non-woven material typically contains many moreengageable fibers than there are hooks per unit area, thus allowing agreater number of disengagements before a hook-and-loop fastener becomesuseless.

Although the stems of the hook strip preferably are generally circularin cross section, other suitable cross sections include rectangular andhexagonal. The stems preferably have fillets at their bases, both toenhance strength and stiffness and for easy release from a mold in whichthey are formed. In addition, the stems can be tapered, preferably froma larger to a smaller cross-section as one moves from the base to thehead.

The stem portions are preferably at an angle of about 90 degrees fromthe backing substrate, however, this angle can range from about 80 toabout 100 degrees, preferably 85 to about 95 degrees. The hook headportion is formed on the distal end of the stem. The hook head can beelongated in on or more directions forming the fiber engaging portions.These fiber engaging portions extend outward from the stem portion atany angle so that they can project upwardly away from the film backing,parallel with the film backing or even downward toward the film backing.

For example, the hook head portion has a deformed fiber engaging portionthat projects downward. Preferably, the lower surface of the fiberengaging portion also projects downward form a crook between the lowerface of the fiber engaging portion and the stem base portion. In onepreferred embodiment, the heads of the hooks generally project at adownward angle from the hook head top portions toward the base. Thisdownward angle (measured from a reference line taken from the top of thehook head and parallel with the backing) is generally from about 0 toabout 70 degrees, preferably from about 5 to about 60 degrees and mostpreferably from about 5 to about 35 degrees (defined by a linear extentrunning from a center region of the hook head top portion to an end ofthe hook head fiber engaging portion).

The head shape with its high diameter to thickness ratio, and the smallsize and close spacing or high density of individual hooks that areprovided by the hook strip according to the present invention makes itable to easily firmly releasably engage non-woven materials in shear,possibly because the many thin heads can easily move radially intoengagement with rather small fibers. Thus the hook strip is particularlyuseful for hook-and-loop fastening when the “loops” are provided bynon-woven materials which are not particularly adapted for use as theloop portions of hook and loop fasteners, and which are not as wellengaged by known prior art hook strips. For example, the hook strip isparticularly well-suited for engaging the topographically flatternon-woven materials described above, including the non-woven spunbondmaterial, which has relatively fewer loose, outwardly extending, freefibers than conventional loop materials, but still provides a relativelyhigh number of pores, of sufficient size, such that the material can beengaged by the hooks. Indeed, once the hooks are received in the pores,or embedded in the non-woven material, the fastening tabs provideexcellent shear characteristics, such that the garment is securelyfastened during normal wearing conditions.

In general, the hooks are of uniform height, preferably of from about0.10 to 1.30 mm in height, and more preferably from about 0.18 to 0.51mm in height; have a density on the backing preferably of from 60 to1,600 hooks per square centimeter, and more preferably from 125 to 690hooks per square centimeter, and preferably greater than about 150 hooksper square centimeter; have a stem diameter adjacent the heads of thehooks preferably of from 0.07 to 0.7 mm, and more preferably from about0.1 to 0.3 mm. The deformed hook heads project radially past the stemson at least one side preferably by an average of about 0.01 to 0.3 mm,and more preferably by an average of about 0.02 to 0.25 mm and haveaverage thicknesses between their outer and inner surfaces (i.e.,measured in a direction parallel to the axis of the stems) preferably offrom about 0.01 to 0.3 mm and more preferably of from about 0.02 mm to0.1 mm. The hook heads have average head diameter (i.e., measuredradially of the axis of the heads and stems) to average head thicknessratio preferably of from 1.5:1 to 12:1, and more preferably from 2.5:1to 6:1.

For most hook-and-loop uses, the hooks of the hook strip should bedistributed substantially uniformly over the entire area of the hookstrip, usually in a square or hexagonal array.

To have both good flexibility and strength, the backing of the hookstrip preferably is from 0.02 to 0.5 mm thick, and more preferably isfrom 0.06 to 0.3 mm in thick, especially when the hook strip is made ofpolypropylene or a copolymer of polypropylene and polyethylene. For someuses, a stiffer backing could be used, or the backing can be coated witha layer of pressure sensitive adhesive on its surfaces opposite thehooks by which the backing could be adhered to a substrate, such as thecarrier member 43, so that the backing could then rely on the strengthof the substrate to help anchor the hooks.

Virtually any orientable thermoplastic resin that is suitable forextrusion molding may be used to produce the hook strip. Thermoplasticresins that can be extrusion molded and should be useful includepolyesters such as poly(ethylene terephthalate), polyamides such asnylon, poly(styrene-acrylonitrile),poly(acrylonitrile-butadiene-styrene), polyolefins such aspolypropylene, and plasticized polyvinyl chloride. One preferredthermoplastic resin is a random copolymer of polypropylene andpolyethylene containing 17.5% polyethylene and having a melt flow indexof 30, that is available as SRD7-463 from Shell Oil Company, Houston,Tex.

The hook strip has preferably substantially continuous planar backing ofthermoplastic resin. Integral with the backing is the array of hooksprojecting generally at right angles to one major surface of thebacking. Each of the hooks has a stem, and, at the end of the stemopposite the backing, a generally circular plate-like cap or headprojecting radially past or overhanging the stem so as to form a fiberengaging portion that projects downward. Preferably, the lower surfaceof the fiber engaging portion also projects downward form a crookbetween the lower face of the fiber engaging portion and the stem baseportion. The stem can also have a fillet around its base.

When the absorbent garment is secured to the user, the fastening tabs 42secured to the side portions of the front body panels 4 releasablyengage or are otherwise connected to the landing member secured to themiddle portion of the front body panel 4. In particular, the heads onthe hooks engage the fibers in the landing material.

Referring to FIGS. 1 and 4, the absorbent garment includes an absorbentcomposite 50 having first and second longitudinally opposed terminal endedges 60, 62. The absorbent composite preferably includes asubstantially liquid permeable topsheet 64, or liner, and asubstantially liquid impermeable backsheet 68, or outer cover. Aretention portion 70 is disposed or sandwiched between the topsheet andthe backsheet, which are connected. The topsheet, backsheet and othercomponents of the absorbent composite 50 can be joined for example withadhesive bonds, sonic bonds, thermal bonds, pinning, stitching or anyother attachment techniques known in the art, as well as combinationsthereof. For example, a uniform continuous layer of adhesive, apatterned layer of adhesive, a sprayed pattern of adhesive or any arrayof lines, swirls or spots of construction bonds may be used to join thetopsheet and backsheet, or any of the other components described herein.It should be understood that the term “absorbent composite” refers toany material or assembly capable of absorbing liquids or bodilyexudates, and may be comprised of a single material or component, forexample a retention portion.

Additional layers, including for example, a surge layer, are alsopreferably incorporated into the absorbent composite. Preferably, thesurge layer does not run the entire length of the absorbent compositeand is shorter than the retention portion. The topsheet can beindirectly joined to the backsheet by affixing the topsheet tointermediate layers, such as the surge layer or retention portion, whichin turn is affixed to the backsheet. The absorbent composite also mayinclude barrier cuffs, or leakage control shields, formed along theopposite longitudinally extending edges of the absorbent composite.

The backsheet 68 is preferably liquid impermeable, but may be liquidpermeable, e.g., when an additional barrier layer is used with theretention portion. For example, in one embodiment, the backsheet can bemade from a thin plastic film, or other flexible, substantiallyliquid-impermeable material. As used herein, the term “flexible” means amaterial that is compliant and which will readily conform to the generalshape and contour of the body of the user. The backsheet preventsvarious bodily fluids and exudates from wetting or otherwisecontaminating various bedding or outer garments worn by the user overthe absorbent garment. In particular, the backsheet can include a film,such as a polyethylene film, having a thickness of from about 0.012 mmto about 0.051 mm.

In various constructions, the topsheet can comprise various woven ornonwoven materials. For example, the topsheet can be composed of ameltblown or spunbonded web of desired fibers, and may also be abonded-carded web. For example, the topsheet can be made of asubstantially hydrophobic material, and the hydrophobic material mayoptionally be treated with a surfactant or otherwise processed to importa desired level of wettability and hydrophilicity. In one particularembodiment of the invention, the topsheet is a nonwoven, spunbondpolypropylene fabric composed of about 2.8–3.2 denier fibers formed intoa web having a basis weight of about 22 gsm and density of about 0.06gm/cc. The fabric can be surface treated with an operative amount ofsurfactant, such as about 0.28% Triton X-102 surfactant. The surfactantcan be applied by any conventional means, such as spraying, printing,brush coating or the like.

In various constructions, the backsheet can comprise a woven or nonwovenfibrous web layer, which is treated or constructed, partially or wholly,to impart the desired levels of liquid impermeability to selectedregions that are adjacent to or proximate the absorbent retentionportion. For example, the backsheet may include a gas-permeable,nonwoven fabric layer laminated to a polymer film layer which may or maynot be gas-permeable. Other examples of fibrous, cloth-like backsheetmaterials can comprise a stretch thinned or stretch thermal laminatematerial composed of a 0.6 mil (0.015 mm) thick polypropylene cast filmand a 0.7 ounce per square yard (23.8 gsm) polypropylene spunbondmaterial (2 denier fibers). A material of this type has been employed toform the outercover of a HUGGIES® Ultratrim Disposable Diaper, which hasbeen commercially available from Kimberly-Clark Corporation. Thebacksheet can provide the outercover of the article, particularly in thecrotch region. Optionally, however, the article may include a separateoutercover component member, as disclosed herein, which is additional tothe backsheet. The outercover can be joined, for example, to one or moreof the absorbent composite and/or body panels as explained above.

The backsheet may include a micro-porous, “breathable” material whichpermits gases, such as water vapor, to escape from the absorbent garmentwhile substantially preventing liquid exudates from passing through thebacksheet. For example, the breathable backsheet may be composed of amicroporous polymer film or a nonwoven fabric which has been coated orotherwise modified to impart a desired level of liquid impermeability.For example, a suitable microporous film can be a PMP-1 material, whichis available from Mitsui Toatsu Chemicals, Inc., a company havingoffices in Tokyo, Japan; or an XKO-8044 polyolefin film available from3M Company of Minneapolis, Minn. The backsheet may also be embossed orotherwise provided with a pattern or matte finish to exhibit a moreaesthetically pleasing appearance.

In various configurations of the invention, where a component, such asthe backsheet is configured to be permeable to gas while having aresistance and limited permeability to aqueous liquid, the liquidresistant component can have a construction which is capable ofsupporting a selected hydrohead of water substantially without leakagetherethrough. A suitable technique for determining the resistance of amaterial to liquid penetration is Federal Test Method Standard FTMS 191Method 5514, 1978, or an equivalent thereof.

In one preferred embodiment, the backsheet is sufficiently impermeableto liquid and semi-liquid materials to substantially prevent theundesired leakage of waste materials, defined as exudates, including forexample urine and feces. For example, the backsheet member can desirablysupport a hydrohead of at least about 45 centimeters (cm) substantiallywithout leakage. The backsheet member can alternatively support ahydrohead of at least about 55 cm, and optionally, can support ahydrohead of at least about 60 cm, or more, to provide improvedbenefits.

The backsheet and/or outercover also can be extensible. In one preferredembodiment, the backsheet and/or outercover is capable of providing anelongation of at least about 1 cm when subjected to a tensile force of11.8 g/cm, and further provides a substantially permanent deformation ofat least about 20% when subjected to a tensile force of 19.70 g/cm andis then allowed to relax under a zero applied stress for a period of 1minute.

For example, the extensible member can be composed of a necked fiber, acreped fiber, a micro-pleated fiber, polymer films or the like, as wellas combinations thereof. The fabrics may be woven or nonwoven materials,such as spunbond fabrics. One example of a suitable extensible materialis a 60% necked, polypropylene spunbond having a basis weight of about1.2 osy.

The backsheet and/or outercover also can be expandable, for example whenit has one or more folds, e.g., one or more z-folds (not shown), or canbe both extensible and expandable. The term expandable as used hereinmeans to enlarge or to increase the extent or area, lateral and/orlongitudinal, thereof, e.g., by unfolding one or more folds.

The retention portion 70 is preferably made of an absorbent material,which can be any material that tends to swell or expand as it absorbsexudates, including various liquids and/or fluids excreted or exuded bythe user. For example, the absorbent material can be made of airformed,airlaid and/or wetlaid composites of fibers and high absorbencymaterials, referred to as superabsorbents. Superabsorbents typically aremade of polyacrylic acids, such as FAVOR 880 available from Stockhausen,Inc. of Greensboro, N.C. The fibers can be fluff pulp materials, such asAlliance CR-1654, or any combination of crosslinked pulps, hardwood,softwood, and synthetic fibers. Airlaid and wetlaid structures typicallyinclude binding agents, which are used to stabilize the structure. Inaddition, various foams, absorbent films, and superabsorbent fabrics canbe used as an absorbent material. Various acceptable absorbent materialsare disclosed in U.S. Pat. No. 5,147,343 for Absorbent ProductsContaining Hydrogels With Ability To Swell Against Pressure, U.S. Pat.No. 5,601,542 for Absorbent Composite, and U.S. Pat. No. 5,651,862 forWet Formed Absorbent Composite, all of which are hereby incorporatedherein by reference. Furthermore, the proportion of high-absorbencyparticles can range from about 0 to about 100%, and the proportion offibrous material from about 0 to about 100%. Additionally, highabsorbency fibers can be used such as Oasis type 121 and type 122superabsorbent fibers available from Technical Absorbent Ltd., Grimsby,Lincolnshire, United Kingdom.

The retention portion 70 has laterally opposed side edges 74 andpreferably can be made of a single or dual layer of absorbent material.The retention portion preferably has an hour-glass shape with enlargedend regions. Alternatively, the retention portion can include a foldedor multi-layered configuration. The retention portion preferably has alength substantially equal to, or slightly shorter than, the length ofthe absorbent composite. The retention portion can include one or morebarrier layers attached to the absorbent material. In one embodiment, anupper tissue substrate is disposed adjacent the retention portion.Alternatively, a lower tissue substrate can be disposed adjacent anopposite side of the retention portion, or the tissue can completelyenvelope the retention position.

Referring to FIG. 1, the opposite garment side of the end regions of theabsorbent composite, and in particular, the outer, garment side surfaceof the backsheet 68, are secured to the bodyside surface of thelongitudinally opposed crotch ends of the first and second body panels4, 6. It should be understood that the absorbent composite can besecured using any of the methods of attachment described above,including for example various adhesives, stitching or other bondingmethods. The absorbent composite can be secured to the body panels withany configuration of attachment lines, swirls, patterns, spots, etc., orcan be a full and continuous attachment therebetween.

Referring to FIGS. 2–4, the method and apparatus for fabricating one ormore embodiments of the aforedescribed refastenable absorbent garment isillustrated. Although the process is described in terms of variouszones, it should be understood that it is a continuous process.

Referring to FIG. 2 at zone A1, a roll of fastener material 104 providesa continuous supply or strip of fastener material moving in a machinedirection and having a carrier material 106 forming outer lateral baseportions and an engagement material 108 disposed along a middle portionof the carrier material to form the refastenable portion. The strip offastener material is cut along the machine direction, preferably in aserpentine cut, to form a pair of strips 110 of fastener material, eachhaving a plurality of tab members 47 facing laterally inward toward theother strip of fastener material. The strips can be cut using a rotarydie cutter. Referring to zone A2, the strips of fastener material areseparated such that they are laterally spaced in the cross direction.The strips 110 are also aligned, with one or both of the strips beingmoved in the machine direction relative to the other, such that the tabmembers 47 are aligned in the cross direction directly opposite eachother. For example, U.S. Pat. No. 5,540,796, entitled Process forAssembling Elasticized Ear Portions and assigned to Kimberly-ClarkCorporation, the entire disclosure of which is hereby incorporatedherein by reference, discloses one embodiment of the cutting,separating, and aligning process.

Referring to zone A3, a continuous web of landing material 102 isintroduced into the process and moves therealong in a machine direction.The landing material 102 can be made of any of the above-describedmaterials, including for example a point unbonded, nonwoven material ora spunbond nonwoven material. The landing material can also be made ofvarious known loop materials. Alternatively, if the fastener member isconfigured as a tape, the landing material preferably made of variousknown materials that interface with such tape. The landing material hasopposite lateral side edges 112. The pair of strips 110 of fastenermaterial are applied to the landing material along the opposite sideedges 112.

In a preferred embodiment, the refastenable portion 51 of the fastenermaterial is removeably or releasably engaged with the landing material102. For example, in one preferred embodiment, the refastenable portion51 of the fastener material comprises a hook material that is embeddedin the landing material 102. In another embodiment, the refastenableportion comprises a tape or adhesive that is engaged with the landingmaterial. Preferably, the base portion 114, or at least a portionthereof, of the fastener material extends laterally outboard oroutwardly beyond the opposite side edges 112 of the landing material. Itshould be understood that the fastener material can be comprised of asingle material that forms both the base portion and the refastenableportion, and that the term “base portion” is meant to refer to thatportion of the fastener material that is secured to the front panel 4 onthe outboard side of the line of weakness 37, preferably in anonremovable relationship thereto. Preferably, engagement between therefastenable portion of the fastener material and the landing material,whether it be of a hook and loop engagement or an adhesive engagement,is the only type of engagement between those two members. In oneembodiment, a nip can be used to facilitate the engagement between therefastenable portion and the landing material. Of course, it should beunderstood that the fastener material could be otherwise secured to thelanding material by a device other than the refastenable portion, forexample by using additional bonds or adhesives that can be broken whenthe garment is in use.

Referring to FIG. 3 and zone A4 of FIG. 2, the landing material 102,with the fastener material 104 removeably secured thereto by way of theengagement between the refastenable portion and the landing material, issuccessively cut along the cross direction to form a plurality ofdiscrete landing members 100, each having a pair of fastener members 42secured to the opposite side edges thereof. As shown in FIG. 3, forexample, a perforation cut 118 can be made with a cutter 119. Anadhesive applicator 121 can apply an adhesive to the body side surfaceof the landing material upstream of the cutter 119, as shown in FIG. 3,or downstream thereof after the landing members have been formed anddefined. The cut alternatively can be a continuous cut, e.g. a slit, soas to completely separate successive landing members and fastenermembers, which preferably are carried on a conveyor, or it can be aperforation cut. Preferably, the cuts are made such that each fastenermember 42 is formed with two tab members 47 having a pair ofrefastenable portions 51. Of course, it should be understood that thecuts can be spaced such that the fastener member has a single tabmember, or more than two tab members.

Referring to FIGS. 2 and 3, and in particular zone A5, each of thelanding members 100 and fastener members 42, whether separatedcompletely from the next successive landing member and fastener members,or partially connected thereto by way of a perforation, is rotated andaccelerated and applied to a body panel base web 120 moving along in theprocess in a machine direction. In one alternative embodiment, therotator cuts the landing material and fastener material and separatesthe resultant landing members and fastener members. The base web ispreferably moving at a greater speed than the landing material. The baseweb is made of one or more of the materials described above with respectto the body panels and preferably is made of a spunbond nonwovenmaterial. The landing member 100, which is preferably elongated in thecross direction prior to rotation, is rotated such that it is elongatedin the machine direction, with the opposite pairs of fastener members 42forming the leading and trailing edge of a refastenable subassembly 122,which is comprised of a landing member 100 and a pair of fastenermembers 42, as it travels in the machine direction.

As shown in FIG. 3, the refastenable subassembly is rotated using anoffset cam action rotator 124. The rotator includes a plurality oftransfer segments 126, which can have a vacuum applied thereto, thatengage the refastenable subassembly 122. Coupler arms 127 connect thetransfer segments and a drive ring. The coupler arm 127 includes a camend having a cam follower that follows the profile of a cam mechanism.The profile of the cam mechanism can be readily changed to change thedesired speed output and pitch of the fastener members. Preferably, thelanding material, with the fastener material removeably secured thereto,or the stream of refastenable subassemblies, are moving at a slowerspeed than the speed of the body panel web. The rotator is configured toaccelerate the refastenable subassemblies. If the successivesubassemblies 122 are separated by a perforation, the transfer segment126 breaks the perforation as it engages the subassembly and moves awayfrom the next subassembly 122, which is engaged by a next transfersegment 126. The rotator rotates the end portion of the transfersegment, preferably approximately 90 degrees, about a radial axis, suchthat the subassembly is oriented in the machine direction as describedabove as the transfer segments are rotated about a horizontal axis 128.Alternatively, the landing material and fastener material are cut andseparated by the transfer segments. The rotator, and the method for theuse thereof, is further disclosed in U.S. Pat. Nos. 5,761,478,5,759,340, and 6,139,004, all of which are assigned to Kimberly-ClarkWorldwide, Inc., the assignee of the present application, and the entiredisclosures of all of which are hereby incorporated herein by reference.Alternatively, the subassembly can be rotated using a revolving transferroll as shown and described in U.S. Pat. No. 4,608,115, which isassigned to Kimberly-Clark Worldwide, Inc., the assignee of the presentapplication, and which is hereby incorporated herein by reference in itsentirety.

Referring to FIG. 2, the base web, which preferably forms the front bodypanel, and which is preferably made of one or more of the materialsdescribed above, is moved along in the process in the machine direction.At zone B1, an adhesive is applied to one side of the base web.Preferably, the adhesive is applied as a continuous adhesive layer, orintermittently as a continuous adhesive layer 128 and a microbeadadhesive layer 130. Alternatively, the adhesive can be appliedintermittently, with ultrasonic bonds connecting the substrates in theregions between the application of adhesive. The adhesive is preferablyapplied intermittently only when a landing member is being applied overthe area of no adhesive or the area of microbead adhesive, which areasalso preferably include deadened elastic elements.

Referring to FIG. 2 (zone B2), the plurality of elastic elements 36 areapplied between a body panel base web 120 liner and an outer base weblayer with an elastic applicator in one or more of the configurationsdescribed above. The body panel web 148 shown in FIG. 4 can befabricated in a similar fashion. The outer base web layer, which can beformed from the outer cover, is adhered to the liner with the adhesive,or with other known devices such as ultrasonic bonds, thermal bonds,stitching and the like. For example, as shown in FIG. 1, the elasticelements are applied in the machine direction as they are spaced acrossthe entire length (defined in the cross direction) of the waist portionof the body panel base web. In particular, the elastic elements areapplied between two substrates of the base web, e.g., a front body panelliner substrate and an outer cover substrate. At the same time, elasticelements are applied to another base web 148, e.g., the rear body panel,running parallel to the first base panel. The body panel web, with theelastic elements disposed between the two substrates, is passed througha nip. Various aspects for fabricating the absorbent garment, and forintroducing the elastic elements, are shown and described in U.S. Pat.No. 5,643,396, which is hereby incorporated herein by reference.

Referring to FIGS. 2 and 3, and in particular zone B3, the elasticelements 36 are deactivated in the landing zone 17 with a timed elasticcutter 132, preferably by severing or chopping the elastic elements. Inzone B4, a pair of machine direction spaced cross direction cuts 140 aremade in the base web with a cutter 138 to form the lines of weakness 37,preferably in the landing zone and preferably spaced inwardly from theoutboard edges of the landing zone. The cutter can be a knife and anvilcutter, or a laser, water jet or other type of cutter known to those ofskill in the art.

Referring to FIGS. 2 and 3, and in particular zone C1, the refastenablesubassembly 122 is applied to the base web with the rotator 124 as thebase web 120 wraps around a construction drum 134. In particular, thelanding member 100 is applied to the base web 120 in the landing zone 17between the lines of weakness 37, or perforation cuts 140. The landingmember 100 is held to the base web 120 with adhesive, which is appliedto the landing member, or landing material if not cut, by applicator121. At the same time the landing member 100 is being applied to thebase web, the base portion 55 of the fastener members, or that portionof the fastener member extending beyond the side edge of the landingmember, are secured to the base web 120, preferably in the landing zone17, with the base portion 55 also being adhered to the base web withadhesive, which was previously applied thereto. The base portion 55 isapplied to the base web 120 on the opposite side of the line of weakness37 that the landing member 100 is applied, such that the fastener member42 spans the line of weakness 37. The base web 120, with the subassembly122 applied thereto, passes through a nip 136, which further bonds thesubassembly to the base web.

Referring to FIG. 3, the fastener members 42, once applied to the bodypanel base web 120 with the rotator 124, are preferably bonded to thebody panel web using one or more, and preferably two, bonders 620, andpreferably ultrasonic bonders. An exemplary ultrasonic bonder is therotating horn and anvil type ultrasonic bonder disclosed in U.S. Pat.No. 5,660,679, the entirety of which is hereby incorporated herein byreference. Another type of ultrasonic bonder is disclosed in U.S. Pat.No. 6,123,792, the entire disclosure of which is hereby incorporatedherein by reference. It should be understood that the fastener memberscan be secured to the body panel webs with other adhesives, stitching,and/or other types of attachment known to those of skill in the art.

Referring to FIG. 4, and in particular, zone D1, the base web 120 isfurther secured to the absorbent composite 50, which is also secured toa base web 148 that forms the rear body panel. In particular, the frontpanel base web 120 moves along a path parallel to the back panel baseweb 148 in machine direction. The absorbent composite 50, extending inthe cross direction, is then applied to the bodyside of each of thefront and rear body panel base webs 120, 148 to form a ladder typeconfiguration, although it should be understood that the absorbentcomposite could be attached to the garment side of each body panel. Theabsorbent composite 50 is secured to the body panel base webs 120, 148by bonding and the like, or by other devices known to those of skill inthe art.

In an alternative embodiment, an outer cover can be secured to one ormore body panel liners and form part of the front and rear body panelsand a crotch portion of the absorbent garment. In this embodiment, a diecutter cuts leg openings in the outer cover between the absorbentcomposites, and can also be configured to further define the shapes ofthe body panels.

At zone D2, the absorbent composite 50 is folded such that the rear bodypanel base web 148 overlies and faces the front body panel base web 120.Side seams 39 are formed with a side seal bonder, preferably byultrasonic bonding, or with adhesive bonds, stitching or other suitablemeans known to those skilled in the art. At zone D3, a cross directioncut 150 is made through the side seam to separate the refastenableabsorbent garments. The cut can be made with a knife and anvil.

Various aspects of the process for making the absorbent garment arefurther disclosed in U.S. application Ser. No. 09/834,870, filed Apr.13, 2001, and entitled “Multiple Component Web,” U.S. application Ser.No. 09/834,875, filed Apr. 13, 2001 and entitled “Method of AssemblingPersonal Care Absorbent Article,” U.S. application Ser. No. 09/834,869,filed Apr. 13, 2001, and entitled “Pant-Type Personal Care Articles, andMethods of Making and Using Such Personal Care Articles,” U.S.application Ser. No. 09/834,787, filed Apr. 13, 2001 and entitled“Methods of Changing Size of Pant-Type Personal Care Articles Outputtedfrom a Manufacturing Process,” and U.S. application Ser. No. 09/834,682,filed Apr. 13, 2001 and entitled “Passive Bonds For Personal CareArticle,” the entire disclosures of which are hereby incorporated byreference.

In other aspects, the absorbent garment and the process for making theabsorbent garment are further disclosed in U.S. Provisional ApplicationSerial No. 60/303,307, filed Jul. 5, 2001, and entitled “RefastenableAbsorbent Garment,” the entire disclosure of which is herebyincorporated by reference.

Although the present invention has been described with reference topreferred embodiments, those skilled in the art will recognize thatchanges may be made in form and detail without departing from the spiritand scope of the invention. As such, it is intended that the foregoingdetailed description be regarded as illustrative rather than limitingand that it is the appended claims, including all equivalents thereof,which are intended to define the scope of the invention.

1. An apparatus for fabricating a refastenable absorbent garmentcomprising a base web having a plurality of elastic members, a piece oflanding material attached to the base web and a fastener memberremoveably attached to the piece of landing material and fixedlyattached to the base web, the apparatus comprising: a web perforatoradapted to perforate the base web in a cross direction; a constructiondrum positioned downstream of said web perforator and adapted to receivethe perforated base web; a landing material cutter adapted to cut alanding material and a fastener material in the cross direction andthereby form a plurality of the pieces of landing material with aplurality of the fastener members secured thereto respectively; and alanding member rotator positioned adjacent said construction drum anddownstream of said landing material cutter, wherein said landing memberrotator is adapted to separate successive pieces of landing materialwith the fastener members attached thereto at the cross directionlanding material cut, rotate the piece of landing material with thefastener member attached thereto and apply the piece of landing materialand the fastener member to the base web on the construction drum.
 2. Theapparatus of claim 1 further comprising an elastic deactivatorpositioned upstream of said web perforator and adapted to deactivate atleast a portion of the plurality of elastic members.
 3. The apparatus ofclaim 1 wherein said landing material cutter comprises a perforator. 4.The apparatus of claim 1 further comprising a nip positioned downstreamof said landing member rotator, said nip adapted to bond the piece oflanding material to the base web.
 5. The apparatus of claim 4 whereinsaid nip is formed in part by said construction drum.
 6. The apparatusof claim 1 further comprising a bonder positioned downstream of saidconstruction drum, wherein said bonder is adapted to fixedly secure thefastener member to said base web.
 7. The apparatus of claim 6 whereinsaid bonder comprises an ultrasonic bonder.
 8. The apparatus of claim 1further comprising an adhesive applicator positioned upstream of saidlanding member rotator, said adhesive applicator adapted to apply anadhesive to the landing material.
 9. The apparatus of claim 8 whereinsaid adhesive applicator is positioned upstream of said landing materialcutter.
 10. The apparatus of claim 1 wherein said rotator comprises acam action rotator.
 11. An apparatus for fabricating a refastenableabsorbent garment comprising a base web having a plurality of elasticmembers, a piece of landing material attached to the base web and afastener member removeably attached to the piece of landing material andfixedly attached to the base web, the apparatus comprising: a webperforator adapted to perforate the base web in a cross direction; aconstruction drum positioned downstream of said web perforator andadapted to receive the perforated base web; a landing material cutteradapted to cut a landing material and a fastener material in the crossdirection and thereby form a plurality of the pieces of landing materialwith a plurality of the pieces of fastener members secured thereto; alanding member rotator positioned adjacent said construction drum anddownstream of said landing material cutter, wherein said landing memberrotator is adapted to separate successive pieces of landing materialwith the fastener members attached thereto at the cross directionlanding material cut, rotate the piece of landing material with thefastener member attached thereto and apply the piece of landing materialand the fastener member to the base web on the construction drum; anadhesive applicator positioned upstream of said landing member rotator,said adhesive applicator adapted to apply an adhesive to the landingmaterial; and a bonder positioned downstream of said construction drum,wherein said bonder is adapted to fixedly secure the fastener member tosaid base web.
 12. The apparatus of claim 11 further comprising anelastic deactivator positioned upstream of said web perforator andadapted to deactivate at least a portion of the plurality of elasticmembers.
 13. The apparatus of claim 11 wherein said landing materialcutter comprises a perforator.
 14. The apparatus of claim 11 furthercomprising a nip positioned downstream of said landing member rotator,said nip adapted to bond the piece of landing material to the base web.15. The apparatus of claim 14 wherein said nip is formed in part by saidconstruction drum.
 16. The apparatus of claim 11 wherein said bondercomprises an ultrasonic bonder.
 17. The apparatus of claim 11 whereinsaid adhesive applicator is positioned upstream of said landing materialcutter.
 18. The apparatus of claim 11 wherein said rotator comprises acam action rotator.